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If you have access to the December 2005 issue of Military Vehicles Magazine, "The highway deuce" article covers light and other potential problems when on the road.

Don't know anything about that, I'd bench test the units under ideal conditions before installing, if it was me. Plastic tail light housings may need more than one terminal grounded (mounting screw).

Actually, higher resistance will reduce the current, but increase the voltage drop across the junction and leave little or no voltage across the light filament (=make it dim). Most LED lights have built-in voltage regulators but will "blow" if the voltage is to high.

The rating of the light switch CB is 20 amps. Do the smart thing and separate the headlight circuit from the rest of the lights. It is not fun when it happens at night.